Vehicle Bumper Crash Box Towing Eyelet Attachment
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Solution Overview
Problem
The attachment of a towing eyelet to one side of a car bumper adversely affects the deformation properties of the crash box due to asymmetrical loading, as existing designs do not allow for stable attachment without compromising the crash box's structural integrity.
Innovation Solution
A tapered crash box with a welded-on cover and a coaxial hole system, featuring an internally threaded sleeve that supports the bumper bar and provides a stable attachment point for the towing eyelet without altering the crash box's deformation properties, allowing for symmetrical loading and minimal impact on crash box deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a towing eyelet is attached to one crash box, then the towing function is achieved, but the deformation properties of the crash box are adversely affected
Solution Approach 1:
The attachment system is segmented into separate components: the crash box remains structurally independent while the towing eyelet is mounted on a cover plate attached to the bumper bar. This segmentation allows the crash box to maintain its deformation properties while the towing function is provided by the separate eyelet assembly.
Solution Approach 2:
The cover plate serves as an intermediary element between the bumper bar and the towing eyelet. It provides a mounting surface for the eyelet while being attached to the bumper bar at a location that does not interfere with the crash box's deformation characteristics.
2Reliability
If the towing eyelet is attached directly to the crash box, then the attachment is stable, but the crash box's structural integrity is compromised
Solution Approach 1:
The attachment system is divided into separate functional elements: the crash box for structural integrity and the cover plate with eyelet for stable attachment. This allows each component to fulfill its specific function without compromising the other.
Solution Approach 2:
The towing attachment function is extracted from the crash box structure and placed on a separate cover plate. This extraction allows the crash box to maintain its structural integrity while the towing eyelet provides stable attachment on its own mounting surface.
3Adaptability or versatility
If asymmetric attachment is used, then the towing function is provided, but the crash boxes have different deformation properties
Solution Approach 1:
The cover plate design is universal and can be applied to either or both crash boxes without affecting their symmetry. The same attachment mechanism can be used on both sides, allowing for symmetrical loading while providing the towing function where needed.
Solution Approach 2:
The attachment system is applied locally on the bumper bar through the cover plate rather than being integrated into the crash box structure. This local application allows for asymmetric or symmetric configuration as needed while maintaining the crash boxes' identical deformation properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables stable and symmetrical attachment of the towing eyelet, maintaining the deformation properties of the crash box and ensuring consistent structural integrity, even when only one crash box is equipped with the attachment mechanism.
Implementation Method 1
an internally threaded sleeve welded at least to one or other of the cover and the bumper bar
Data Source
Figure 1~2
Figure 3~4
AI summary
A bumper includes a bumper bar (14) and two crash boxes (11) welded to the bumper bar, one of the crash boxes having an inwardly threaded sleeve (17) serving as an attachment means for a towing eyelet. A mounting plate (13) is welded to the outer end of the crash box, thereby serving as a cover, and to the bumper bar (14). The mounting plate has an indentation with a hole to the edges (18) of which the sleeve (17) is welded and the sleeve is supported against the edge (19) of a hole in the bumper bar at an axial distance from the point at which it is welded to the mounting plate.